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GREENSTAR 12Ri ErP, Installation, Commissioning And Servicing Instructions

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GREENSTAR 12Ri ErP Installation, Commissioning And Servicing Instructions Download Page 2

CONTENTS

Greenstar Ri 

ErP

 - 6 720 813 283 (2015/07)

2

CONTENTS

1

KEY TO SYMBOLS AND SAFETY PRECAUTIONS . . . . . . . . . . . . 3

1.1

Key to symbols  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2

Safety precautions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2

Regulations  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3

APPLIANCE INFORMATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1

Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.2

Technical data  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3

Energy efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.4

Boiler main components . . . . . . . . . . . . . . . . . . . . . . . .  10

4

PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11

4.1

Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . .  11

4.2

Mains supply  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11

4.2.1

Electrical supply  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11

4.2.2

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11

4.3

Water systems and pipe work . . . . . . . . . . . . . . . . . . . .  11

4.4

Condensate pipe work  . . . . . . . . . . . . . . . . . . . . . . . . .  13

4.4.1

Internal connections  . . . . . . . . . . . . . . . . . . . . . . . . . . .  13

4.4.2

External connections  . . . . . . . . . . . . . . . . . . . . . . . . . .  14

4.5

PRESSURE RELIEF PIPE WORK  . . . . . . . . . . . . . . . . . .  15

4.6

Boiler location and clearances  . . . . . . . . . . . . . . . . . . .  15

4.6.1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  15

4.6.2

Servicing clearances - 
Ventilated compartment  . . . . . . . . . . . . . . . . . . . . . . . . 15

4.6.3

Compartments: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  16

4.6.4

Boiler clearances- Unventilated compartments  . . . . .  16

4.6.5

Installation clearances - unventilated compartments .  16

4.6.6

Bathrooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  16

4.7

Plumbing manifold  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  17

4.7.1

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  17

4.8

FLUE OPTIONS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18

4.8.1

Flue lengths  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18

4.9

Flue terminal positions  . . . . . . . . . . . . . . . . . . . . . . . . .  20

4.10

Plume management terminal positions  . . . . . . . . . . . .  21

4.10.1 Determine the plume management system length  . . .  22

5

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  22

5.1

Unpacking the wall frame & ancillary items . . . . . . . . .  22

5.2

Wall mounting template & flue opening . . . . . . . . . . . .  23

5.3

Outer case removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .  24

5.4

Boiler connection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  24

5.4.1

Condensate connection  . . . . . . . . . . . . . . . . . . . . . . . .  25

5.5

Flue turret/adaptor installation  . . . . . . . . . . . . . . . . . .  26

5.6

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . .  27

6

COMMISSIONING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6.1

Pre-Commissioning checks  . . . . . . . . . . . . . . . . . . . . . . 28

6.2

Filling the system  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.3

Water treatment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.4

Starting the appliance  . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.5

Commissioning  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.5.1

Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . . 30

6.5.2

Checking the gas rate  . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.6

CO and Combustion checks . . . . . . . . . . . . . . . . . . . . . . 31

6.7

Finishing commissioning  . . . . . . . . . . . . . . . . . . . . . . . . 32

6.7.1

Replace the outer case:  . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.7.2

Install the bottom panel  . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.7.3

Hand over  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.7.4

Appliance guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

7

SERVICE AND SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7.1

Inspection and service  . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7.2

Checking gas inlet pressure  . . . . . . . . . . . . . . . . . . . . . . 34

7.3

Checking flue integrity  . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7.4

Fan pressure test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7.5

Flue gas analysis  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7.6

Setting the air/gas ratio  . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.6.1

Setting the CO/CO2  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.7

Cleaning the heat exchanger  . . . . . . . . . . . . . . . . . . . . . 36

7.7.1

Syphon removal and cleaning  . . . . . . . . . . . . . . . . . . . . 38

7.8

Replacement of parts  . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.8.1

Removing the outer casing . . . . . . . . . . . . . . . . . . . . . . . 39

7.8.2

Primary sensor (CH NTC) . . . . . . . . . . . . . . . . . . . . . . . . 39

7.8.3

Overheat thermostat  . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.8.4

Flue overheat thermostat
(with grommet)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.8.5

Lowering the boiler controls to the service position:  . . 40

7.8.6

Gas valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.8.7

Air/gas manifold and fan assembly  . . . . . . . . . . . . . . . . 41

7.8.8

Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.8.9

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.8.10 Electrode assembly and burner . . . . . . . . . . . . . . . . . . . 43
7.8.11 Re-assembly of the burner clamping plate  . . . . . . . . . . 43
7.8.12 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.8.13 Syphon removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.8.14 Access to boiler control components  . . . . . . . . . . . . . . 45
7.8.15 PCB Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.8.16 Code plug  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.8.17 Transformer/PCB  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.9

Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

8

FAULT FINDING AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 48

8.1

Fault finding  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

8.1.1

Internal wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8.2

Boiler function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.3

Protection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Summary of Contents for 12Ri ErP

Page 1: ...If you smell gas Well away from the building call the National Gas Emergency Service on 0800 111 999 L P G boilers Call the supplier s number on the side of the gas tank These appliances are for use w...

Page 2: ...lectrical connections 27 6 COMMISSIONING 28 6 1 Pre Commissioning checks 28 6 2 Filling the system 29 6 3 Water treatment 29 6 4 Starting the appliance 29 6 5 Commissioning 30 6 5 1 Checking the gas i...

Page 3: ...RTING INSTALLATION Warnings in this document are identified by a warning triangle printed against a grey background Keywords at the start of a warning indicate the type and seriousness of the ensuing...

Page 4: ...for more information Health and safety The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations Control of Substances Haza...

Page 5: ...lies for domestic purposes EN12828 Central heating for domestic premises BS5440 1 Flues and ventilation for gas appliances of rated heating not exceeding 70kW net Flues BS5440 2 Flues and ventilation...

Page 6: ...1 Wall hung gas fired condensing regular boiler for central heating and domestic hot water 2 Tail pipes water only 3 Wall plate 4 Hardware literature pack see checklist 5 ErP Label 6 Bottom panel and...

Page 7: ...66 59 71 61 79 64 Flue gas temp 40 30 C rated min load C 41 33 44 33 48 34 54 35 43 35 46 36 49 37 55 38 CO2 level at max rated heat output after 30 min 9 65 9 8 9 8 9 8 11 0 11 0 11 0 11 0 CO2 level...

Page 8: ...regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 12 15 18 24 At 30 of rated heat output and low temperature regime 2 2 Low temperature means for c...

Page 9: ...urn temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 12 15 18 24 At 30 of rated heat output and low temperature regime 2 2 Low temperature means for condensing boilers 30 C...

Page 10: ...mbly 20 Syphon Trap 7 Overheat thermostat 21 Gas inlet connection 8 Silicon tube Heat Exchanger air vent 22 Mains cable inlet 9 Heat Exchanger 23 Gas Valve 10 Flue overheat thermostat 24 Flue air pres...

Page 11: ...3 phase supply IP20 Wiring must comply with the latest edition of BS 7671 IET wiring regulations 4 2 2 GAS SUPPLY To ensure that the equipment is in good working order and can meet the gasflowandpres...

Page 12: ...assisnotnecessaryonaYplansystem as one of the ports is open to flow 1 Static head Minimum static head 250mm measured from the highest point in the heating system top surface of the appliance or the hi...

Page 13: ...would be required to reach a suitable discharge point condensate should be removed using a proprietary condensate pump of a specification recommended by the boiler or condensate pump manufacturer The...

Page 14: ...chill at the open end The use of a drain cover such as those used to prevent blockage by leaves may offer further protection from wind chill Pipe drainage will be improved if the end is cut at 45 as o...

Page 15: ...ner can gain clear and safe access to the controls check top up or reset the appliance Products in loft cavities must have permanent fixed lighting a permanentfixedretractableladderandafixedfloorareas...

Page 16: ...space required to install and service the boiler inside an unventilated compartment CAUTION CLEARANCES Top and bottom clearances must not be reduced below the values shown in table 12 as they are the...

Page 17: ...mbing manifold Fig 19 Pipe work dimensions Heating System 22mm compression fittings Gas 22mm compression fittings Do not use the pre formed copper pipes supplied with the boiler for the gas supply The...

Page 18: ...hould be viewable from both directions NOTICE Effective flue lengths each90 bendisequivalentto2metresofstraightflue each 45 bend is equivalent to 1 metre of straight flue Plume management kits are ava...

Page 19: ...um flue length mm 60 100 80 125 High level horizontal flue with 2 x 90 bends 2 600 11 000 Table 23 Maximum flue length mm 60 100 80 125 High level horizontal flue with 3 x 90 bends N A 9 000 Table 24...

Page 20: ...tters pipe and drains 16 The dimension below eaves balconies and car ports can be reduced to 25mm as long as the flue terminal is extended to clear any overhang External flue joints must be sealed wit...

Page 21: ...00mm clearance 8 Clearances no less than 200mm from the lowest point of the balcony or overhang 9 1 200mm from an opening in a car port on the same wall e g door or window leading into the dwelling 10...

Page 22: ...d sleeve 6 5 Remove the plastic cover 7 Fig 25 Unpacking 2 Note Measurement M plume length Mmustbeaminimumof500mmandmustnotexceed 4 500mm for a 60mm plume management system used with the horizontal 60...

Page 23: ...levant safety precautions must be undertaken Protective clothing footwear gloves and safety goggles must be worn as appropriate FIXING THE MOUNTING FRAME Theboilertemplateshowstherelativepositionsofth...

Page 24: ...he appliance it is possible to fit the flow and return pipes supplied with the boiler installed on the wall If clearance is less than 600mm below the appliance it may be necessary to fit the flow and...

Page 25: ...n the fitting pack 1 Fit washer 1 inside the plastic nut and attach firmly to the connection on the syphon 2 Connect the condensate disposal pipe work to the elbow 2 refer to figure 31 and insert the...

Page 26: ...ptor kit are used to secure turret adaptor to the appliance Fig 33 Flue turret adaptor connection Additional notes and reminders Ensure that all cut lengths are square and free from burrs Ensure that...

Page 27: ...iler Demand from external wiring centre ST2 Connect SWITCHED LIVE wire to terminal LR Fig 35 Wiring detail NEW COMPLETE SYSTEM INSTALLATIONS Ifanewcomplete heatingsystemisinstalled inanewbuild propert...

Page 28: ...gas pipe work connections and rectify any leaks Check that the condensate pipe has been connected to the syphon Ensurethatthecondensatepipehasbeeninsertedatleast25mminto the elbow Fig 39 Condensate c...

Page 29: ...s and drain the system while the appliance is hot Close drain cocks and add a suitable flushing agent at the correct strength for the system condition in accordance with the manufacturer s instruction...

Page 30: ...en the screw in the inlet pressure test point 1 and connect a manometer Open gas isolation valve Measure the pressure with the boiler running at maximum Refer to section 7 4 to set the boiler to maxim...

Page 31: ...heck flow chart NOTICE BEFORE CO AND COMBUSTION CHECKS Refer to section 6 5 1 and 6 5 2 to verify gas type gas inlet pressure and gas rate Visually check the integrity of the whole flue system and con...

Page 32: ...n Commissioning and Service manual with the Benchmark checklist and service record is left with the boiler or homeowner Iftheapplianceisunusedandexposedtofreezingconditions shutoff all the mains suppl...

Page 33: ...t Finding on page 48 for rectification procedures COMPONENT ACCESS Removing outer case 1 Undo and remove two screws securing boiler casing at the top of the appliance 2 Undo but do not remove the two...

Page 34: ...Fig 51 Flue integrity test 7 4 FAN PRESSURE TEST SETTING THE BOILER TO MAXIMUM 1 Remove the three screws retaining the control cover 2 Remove the control cover 3 Remove the plastic tool clipped inside...

Page 35: ...7 5 FLUE GAS ANALYSIS COMBUSTION TEST Connect the flue gas analyser to the flue gas sampling point as shown in the figure below Run the boiler at maximum output for at least 10 minutes Check the CO CO...

Page 36: ...taining plate assembly Fig 59 Securing nut NOTICE THE SETTING OF THE GAS RATIO MUST BE CARRIED OUT BY A COMPETENT PERSON SETTING OF THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS THE PERSON CARRYING OUT T...

Page 37: ...d cleaning the electrode assembly Inspect the condition of the electrodes and ceramics replace if necessary Use a plastic scouring pad to clean the electrodes BAFFLE REMOVAL 1 Refer to figure 62and re...

Page 38: ...AND CLEANING To release the syphon from the sump 1 Undo the plastic nut on the bottom of the syphon and move the condensate pipe away from the syphon 2 Remove the two screws retaining the syphon brac...

Page 39: ...lace 7 8 3 OVERHEAT THERMOSTAT Refer to figure 68 for removal Remove two electrical connectors from thermostat 3 Slacken and remove fixing screw and thermostat 3 When replacing ensure thermostat sits...

Page 40: ...flue limit thermostat in from the sump Retrieve the thermostat from the sump well Fig 70 Remove thermostat To replace push the thermostat and new grommet gently back into the opening until contact wi...

Page 41: ...sembly 1 around the top of the heat exchanger until the lug on the air gas manifold is visible Lift up assembly and remove from boiler Fig 75 Rotate the air gas manifold assembly NOTICE The valve will...

Page 42: ...the screw holding the retaining plate 4 Remove the retaining plate 5 Remove three screws and the mixing chamber Re assemble with new fan ensuring seals are correctly fitted Fig 78 Dismantling the air...

Page 43: ...lamping plate and the top of the heat exchanger refer to figure 81 Fig 81 Initial location of the clamping plate 1 Retaining plate assembly 2 Clamping plate 3 Gasket 4 Bracket 5 Underside view of the...

Page 44: ...anti clockwise to release from the hook 3 Pull the upper exhaust connector down Fig 85 Upper exhaust assembly 1 Refer to figure 86 and release the clip 2 Move the lower exhaust connector up Remove the...

Page 45: ...ket 2 The code plug should be left attached to the frame of the boiler by its plastic safety thread 7 8 17 TRANSFORMER PCB To change either the PCB F2 fuse or transformer Remove two screws securing th...

Page 46: ...board Re assemble in reverse order NOTICE CODE PLUG Ensure that the code plug is fitted to the new control The appliance will indicate an error and will not function correctly NOTICE CO CO2 After com...

Page 47: ...burner WB6 8 716 110 534 0 Seal Inner case mantel 8 716 106 635 0 H26 545 Flow temperature sensor NTC 8 716 106 688 0 GC No H26 542 Air pressure switch 8 716 106 633 0 G C No H26 543 Seals kit 8 716...

Page 48: ...t ST2 terminal LR is there a demand Manual bypass is open If CH is working check HW controls If HW is working check CH controls i e external diverter valve frost stat room stat programmer Otherwise re...

Page 49: ...fuse AC 230 V Slow T1 25 A fuse CH TEMPERATURE CONTROL PRESSURE SWITCH 230V WIRING CENTER JUNCTION BOX FAN Colour sequence SL L N Min Max Norm ON OFF SWITCH 230V AC 25V Red Blue Violet Orange Live Ne...

Page 50: ...CKOUT 45 second stabilisation period Fan modulation to achieve set temperature 40 82 C END OF BOILER DEMAND Gas valve OFF Pump run 3 minutes Fan run 30 seconds Over temperature shut down if water temp...

Page 51: ...overrun period Internal boiler temperature rises above 12 C Central heating demand switches off Pump switches off after a 3 minute overrun period Central heating demand is activated Pump runs for 3 mi...

Page 52: ...Greenstar Ri ErP 6 720 813 283 2015 07 52 NOTES...

Page 53: ...Greenstar Ri ErP 6 720 813 283 2015 07 53 NOTES...

Page 54: ......

Page 55: ......

Page 56: ...orcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 813 283 2015 07 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0330 123 3366 APPOINTMENTS 0330 123 9339 SPARES 0...

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